Concrete forming apparatus and process

ABSTRACT

A concrete or paving forming apparatus and process comprising laying a concrete or paving material and allowing it to cure into a substantially plastic condition and then imprinting it with a pattern impressed therein in a continuous process. A plastic film, or other suitable release agent permits the forming apparatus to be driven into the concrete in a manner whereby it will not remove the surface of the concrete when it is withdrawn. The apparatus generally comprises a roller with a series of patterns formed by means of blades that conform to the pattern that is to be pressed into the concrete. The roller effectively rolls in the pattern while at the same time a sheet of plastic film is laid down on the concrete ahead of the roller. Thus, as the roller is impressed into the concrete and removed, it will not gouge the concrete. Other release agents such as the silicones or the tetrafluorethylenes can be sprayed on the roller blades or on the concrete to prevent binding and gouging of the pavement.

- United States Patent [191 Moorhead [451 Aug. 27, 1974 CONCRETE FORMINGAPPARATUS AND g I PROCESS Primary Exanu'nerNile C. Byers, Jr. [76]Inventor: William v. Moor-head, 33052 i i Marina Vista Dr., Dana Point,Calif. ABSTRACT 921629 A concrete or paving forming apparatus andprocess [22] Filed: Aug. 10, 1972 comprising laying a concrete or pavingmaterial and allowing it to cure into a substantially plastic conditionAppl' 279709 and then imprinting it with a pattern impressed therein ina continuous process. A plastic film, or other suit- [52] US. Cl 404/72,404/89, 404/ 124 able release agent permits the forming apparatus to be[51'] Int. Cl. E01c 7/35 driven into the concrete in a manner whereby itwill [58] Field of Search 404/84-124, not remove the surface ofthejconcrete when it is with- 404/72, 75, 133, 83 drawn.

- a Y The apparatus generally comprises a roller with a [56] 9References Cited series of patterns formed by means of blades that IUNITED STATES PATENTS conform to the pattern that is to be pressed intothe 519,919 5/1894 .Maurer 404/124 vconcrete- The roller effectivelyrolls i the pattern 1,019,539 3/1912 Sharp 404/93 while at the same timea sheet of plastic film is laid 1,099,185 6/1914 Loveland 404/124 downon the concrete ahead of the roller. Thus, as the 1,974,979 9/l934 Bate404/93 roller is impressed into the concrete and removed it 2,582,199l/l952 vGardner 404/129 X ill not gouge h concrete O h release agentsSuch 3 33233? 2:32? f 232 8; i r as the silicones or thetetrafluorethylenes can be 3:245:478 4/l966 rhzm sii lu.........:I::III104/121 x sprayed i i roller f or on the concrete 3,262,375 7/1966Eigenmann 404/72 Prevent bmdmg and gougmg of the Pavemem- 3,406,618l0/l968 Bowman 404/72 3,459,108 Patterson 404/122 x 5 7 Dramng gCONCRETE FORMING APPARATUS AND PROCESS BACKGROUND OF THE INVENTION 1.Field of the Invention The field of this invention lies within theconcrete forming art.

2. The Prior Art The prior art as it relates to concrete patterns andformation involves numerous concrete patterns that have been formed asmolds for casting a concrete form in situ therein. In other words,different mold configurations and bodies for containing concrete to becast in various forms have been utilized.

Recently, during paving operations it has been desirable to createdifferent patterns in concrete as well as other paving materials. Insome cases, it has been particularly desirable to create patterns whichappear to be in the form of different blocks, bricks, cobblestones andthe like. At times it is desirable for aesthetic purposes to provide anappearance of handlaid bricks, stones, or cobblestones.

The foregoing effect has been effectuated by means of certain hand toolsutilized to strike a pattern into the concrete. Specifically, thegrooves which are normally the struck pattern in concrete between bricksand other stones has been provided by a foot driven impressment tool.

Recent developments in the art have directed themselves to footimpressment tools, for stamping concrete. The stamping process utilizesa series of V- shaped blades which penetrate the concrete when it is ina semi-plastic state so as to effectuate the creation of groovesanalogous to struck portions between bricks and stones. As can beappreciated, any pattern can be effectuated to cause an appearance ofbricks, stones, or other handlaid masonry. It is the aestheticappearance of bricks, stones or other handlaid materials that is desiredby the foregoing processes and apparatus of the prior art.

One of the drawbacks of the prior art with regard to "concrete stampingtools has been the inability to turn out a continuous, inexpensiveproduct. Specifically, the utilization of hand tools requires extensivelabor and substantial effort upon the part of the concrete mason. As aconsequence, the hand stamping" of concrete has only been applied inlimited applications. This invention substantially overcomes thedeficiencies of the prior art by creating a continuous process and anapparatus for carrying out the continuous process. The apparatusutilizes an embossing roller and other attendant support apparatus.

Hand stamping tools have been increased in size to effectuate coverageof broad areas. However, the process is relatively time consumingbecause of the fact that a man can only impress a limited amount ofconcrete as to the square footage that is being impressed. Thisinvention overcomes the limitations of hand stamping concrete byproviding a continuously rollingimpressment. This invention utilizes ameans for preventing the disorientation of the concrete after it hasbeen impressed by virtue of the fact that the shape of the blades do notpull the concrete from its original placement. Furthermore, theinvention utilizes a superior method of providing a buffer between theblades and the concrete as they are impressed into the concrete. Theforegoing allows the blades to effectuate a smooth and non-gouged lookto the groove that has been struck or impressed by the invention.

The blades have a coefficient of friction with respect to thesemi-plastic concrete to the extent that they normally tend to disturbthe concrete as they are being moved. This is particularly true if theblades move laterally within the concrete upon removel from theconcrete. Another consideration is that when the blades are on arotating drum or other rotational means, such as a continuously movingroller, they disturb the concrete as they are being removed. This is notonly due to the coefficient of friction between the blades and theconcrete, but also because of the general character of the rotationalmovement of the blades creating lateral forces. However, the buffer ofthis invention provides a solution to the foregoing problem and tends toeliminate gouging of the concrete.

This invention provides a substantial advance over the prior art bycreating a different process and apparatus for effectuating continuouslyimpressed concrete. The blades of the continuous impressment processeffectuate a striking of the concrete continuously so that substantialhand work need not be utilized in the process. Additionally, theimpressment means creates a smooth surface which is superior to theprior art surfaces-by utilization of the buffer means of this invention,such as the plastic sheet or release agents.

SUMMARY OF THE INVENTION In summation, this invention is a continuousconcrete impressment process and apparatus to provide concrete with asmooth and undisturbed patterned surface.

More specifically, this invention provides a process whereby concretecan be impressed in an easy and fascile mannenThe process incorporates aplacement of concrete in a particular form with an attendant screedingand striking for leveling it off. The surface of the concrete can thenbe tamped, floated and trowled as in prior art processes. The process isthen further effectuated by means of a buffer surface so that acontinuous impressment and rolling of the concrete can take place.

the concrete so that continuity of impressment of the concrete can takeplace.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more clearlyunderstood by reference to the description below taken in connectionwith the accompanying drawings wherein:

FIG. 1 shows a form of apparatus in a perspective view for purposes ofpracticing the invention;

FIG. 2 shows a roller for purposes of practicing this invention as shownalong lines 2-2 of FIG. 1;

FIG. 3 shows a roller having varying configurations similar to that ofFIG. 2 but with a different series of impressment blades;

FIG. 4 shows a sectional view along lines 4-4 of FIG. 2 detailing theconfiguration of the blades of this invention;

FIG. 5 shows an alternative sectional embodiment of the blades of thisinvention;

FIG. 6 shows a plan view of the concrete which has been impressed withthis invention; and,

FIG. 7 shows a plan view of concrete which has been impressed by thisinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The Apparatus Looking moreparticularly at FIG. 1, a motorized tractor I0 is seen overlying aconcrete surface 12 which has recently been poured. The concrete surface12 has been impressed with a pattern seen generally in the areadesignated 14. The impressment has been effectuated by a roller 16having a series of blades 18 that are shown with longitudinal portions20 and lateral portions 22 thereof. A drum surface 17 is utilized tosupport the blades 18. The blades 20 and 22 effectuate an impressment ofthe concrete to provide the pattern generally shown at 14.

The tractor has been provided with tires 24, a frame 25 for support ofthe tractor and the rear roller 16. The tractor 24 is driven by anengine not shown, and has a seat 26 with a back 28 thereto. A steeringwheel 30 is provided coupled into a steering block 32.

The foregoing configuration of the tractor can be in any form, as longas it provides suitable power and mobility for impressment of the blades20 and 22 into the newly laid concrete 12 by means of the roller 16. Asan alternative, the roller 16 can be provided with an attachment as willbe described and hand pushed by means of a handle. Furthermore, theroller can be towed over the uniform concrete surface 12. A sheet ofplastic 34 is provided to aid as a release agent for the blades 20 and22. The sheet of plastic 34 is reeled outwardly from the roll of plastic36 supported on a spindle 38 with frame members 40 holding the spindle38. The sheet 34 is taken up on a second roller 42 supported on aspindle 44 by means of braces 46. The sheet or film 34 is caused to rollaround the takeup roller 42. The film 34 can be paid out from the roller36 in any suitable manner and taken up on the roller 42. An importantconsideration is that a film, buffering surface or release agent be laidbetween the concrete 12 and the roller 16.

In addition to the foregoing film laying apparatus and process, a roller16 can be provided with a means for feeding out a film over its surfacein a continuously driven manner. Also, a plastic polymer or siliconerelease agent can be sprayed onto the newly formed concrete surface 12ahead of the roller, directly onto the roller. In this manner, theroller 16 can impress its blades 20 and 22 into the newly formedconcrete and can be easily removed therefrom without gouging theconcrete.

Although a specific film takeup means has been shown, oftentimes it isnot necessary. In many cases the blades penetrate the film and leave afragmented film impressed against the surface of the concrete. In suchcases, the film has been sacrificed in the process and its only value isscrap.

Other suitable means can be effectuated to provide a buffer between theblades 20 and 22 and the newly poured concrete 12 so as to eliminatedisplacement or gouging of the concrete. Aside from the foregoing film34 that can be used as a buffer, various other materials can be used.For example, various siliconelubricants and release agents can beutilized. The release agents can be sprayed on the roller 16 or directlyon the con crete. In addition to the release agents, the blades 20 and22 can be coated with a fluorinated hydrocarbon such astetrafluorethylene, commonly referred to as teflon. In this manner, theblades will pass into the concrete and not gouge the concrete uponremoval.

Looking more specifically at FIGS. 4 and 5, a series of cross sectionalshowings of the blades are shown. The cross sectional showing in FIG. 4shows a blade 50 having a pointed end 52. The pointed end tapers awayfrom the edges of the blade 50 in chamfers 51 so as to provide asubstantially sharp edge along the upper pointed edge 52. Of course, thedrum surface 17 is utilized to support the blade 50.

Looking more particularly at FIG. 5, a drum surface 17 is shown with anupwardly projecting blade 54 therefrom. The blade has a rounded end 56conforming to a generally curved arcuate configuration. The rounded end56 flows from a pair of oppositely disposed arcuate surfaces 58 whichextend from the upstanding portions of the blade 54.

Many specific configurations of the blades 20 and 22 can be utilized.However, an important consideration is that the blade not displace theconcrete as it moves laterally within its rotational movement. In otherwords, as the blade moves laterally within its arc of movement as it issupported on the drum 17, it should effectuate a path whereby the bladewill not substantially displace the concrete.

The Process The process firstly comprises placement of concrete by meansof any suitable pouring operation. For instance, the concrete can bepoured and initially screeded or struck off to its approximate properlevel at which the concrete is to assume its final form. After theconcrete has been screeded and struck, the concrete is then tamped orvibrated to bring the fine portions thereof to the surface of theconcrete and maintain the more course aggregate displaced below thelevel of the surface.

The surface can then be floated and trowled to allow for a substantiallysmooth and level upper texture of the concrete. The concrete can then bemaintained in this substantially smooth configuration in which it willbe finally impressed and formed with the apparatus and process of thisinvention.

The concrete in many instances is colored by means of a powdered pigmentsprinkled across its surface. In other instances, the concrete can beintegrally colored prior to the time it is poured so that the entirecross section of the concrete is formed as one integrally colored mass.In this manner, different blocks, brick colors and configurations can beutilized for aesthetic appeal providing a configuration and color whichwill suitably approximate the colors of cobblestones, bricks, and otherblocks.

It should be appreciated that the placement of a powdered pigment shouldbe made before the surface is floated and trowled in the eventuality apowdered pigment is used. In this manner, the powdered pigment can thenbe trowled into the upper surface of the concrete.

ln addition to the foregoing means for providing the concrete withcoloration, the concrete can be provided with color by means of acontinuous sprinkling operation in front of the impressment means ofthis invention. In other words, the front portion of the apparatus thatpasses over the concrete prior to the roller 16 or other impressmentmeans can be utilized to sprinkle a pigment on the surface thereof. Thesprinkling can take place with a rotary type of dispenser, or any othersuitable uniform powder sprinkling means. Also, an automatic trowelingof the concrete can be effectuated to drive the coloration into itssurface.

After the concrete has been substantially prepared in the foregoingmanner, it is then rolled by means of a roller 16. Prior to the rollingprocess, a polyethylene film or sheet 34 is laid down so as toeffectuate a surface or buffer between the roller 16 and its blades 20and 22. The buffer can be provided by any particular polymer as long asit provides a suitable buffer. The smooth buffer can be effectuated bymeans of other plastics in the sheet form as shown, or a plastic liquidcan be sprayed on the roller so that a smooth lubricity or releasecapability is provided to the roller 16.

In addition to the foregoing plastic film or liguid, the lubricity orrelease agent can be provided by such compositions as siliconelubricants known in the art today which prevent adhesion of such thingsas elastomers to molds, along with other mold release lubricants. Inaddition to the use of the foregoing release agents, the blades 20 and22 can have a coating of tetrafluorethylene (teflon) on its surface toenhance the release properties thereof.

It should be understood that the foregoing teachings of this inventioncan be broadly utilized to effectuate the capabilities of practicingthis invention. Specifically, the invention can be broadly utilized withany continuous process for pavement impressment and utilization of afilm over the surface thereof. Thus, this invention is only to be readin light of the scope and spirit thereof as defined by the followingclaims.

I claim:

1. In a process for impressing concrete with blades conforming to apre-established pattern, the process steps comprising:

pouring concrete;

leveling said concrete to the approximate surface level to which saidconcrete is to be cured; providing a plastic material over said concreteto form a buffer; and,

impressing a tool with blades into said concrete for simulating separatemasonry elements joned by mortar with said buffer between said bladesand the concrete whereby the frictional engagement between said bladesand said concrete is decreased so that as said blades are withdrawn theywill not substantially disturb said concrete.

2. The process as claimed in claim 1 wherein said buffer comprises:

a plastic sheet.

3. The process as claimed in claim 2 further comprismg:

continuously rotating a tool with blades about an axis of rotation forimpressment thereof into said concrete; and,

paying off said plastic sheet from a roll in a continuous manner so asto allow said blades to strike said plastic sheet and impress themselvesinto said concrete by movement against said plastic sheet into saidconcrete. 7

4. The process as claimed in claim 2 further comprismg:

applying a coloring pigment to the surface of said concrete beforeimpressing said blades; and,

trowling or causing said coloring agent to be impressed into saidconcrete.

5. The process as claimed in claim 1 further comprismg:

spraying a release agent onto said blades prior to their impressmentinto said concrete.

2. The process as claimed in claim 1 wherein said buffer comprises: aplastic sheet.
 3. The process as claimed in claim 2 further comprising:continuously rotating a tool with blades about an axis of rotation forimpressment thereof into said concrete; and, paying off said plasticsheet from a roll in a continuous manner so as to allow said blades tostrike said plastic sheet and impress themselves into said concrete bymovement against said plastic sheet into said concrete.
 4. The processas claimed in claim 2 further comprising: applying a coloring pigment tothe surface of said concrete before impressing said blades; and,trowling or causing said coloring agent to be impressed into saidconcrete.
 5. The process as claimed in claim 1 further comprising:spraying a release agent onto said blades prior to their impressmentinto said concrete.